Robotic heliostat calibration system and method

ABSTRACT

A robotic controller for autonomous calibration and inspection of two or more solar surfaces wherein the robotic controller includes a drive system to position itself near a solar surface such that onboard sensors may be utilized to gather information about the solar surface. An onboard communication unit relays information to a central processing network, this processor combines new information with stored historical data to calibrate a solar surface and/or to determine its instantaneous health.

RELATED APPLICATIONS

This application claims priority from U.S. provisional applicationnumber 61/419,685 filed on Dec. 3, 2010, U.S. utility application Ser.No. 13/118,274 filed May 27, 2011, and US utility application Ser. No.13/182,297 filed Jul. 13, 2011, which are all incorporated by referenceherein in their entirety.

FIELD OF THE INVENTION

The present invention relates to solar tracking and calibration devices,and in particular tracking systems for photovoltaic, concentratedphotovoltaic, and concentrated solar thermal systems that requireconstant repositioning to maintain alignment with the sun.

BACKGROUND OF THE INVENTION

In an attempt to reduce the price of solar energy, many developmentshave been made with respect to lowering the cost of preciselyrepositioning and calibrating a surface with two degrees of freedom. Inconcentrated solar thermal systems, heliostat arrays utilize dual axisrepositioning mechanisms to redirect sunlight to a central tower bymaking the normal vector of the heliostat mirror bisect the anglebetween the current sun position and the target. In order to properlyalign a heliostat's beam to a target, nine parameters must be defined.Three parameters are needed to define the heliostat's location relativeto the receiver target. One parameter is needed to account fortolerances in pan and tilt home positions. One parameter is needed todefine mirror-mounting offsets, and an additional parameter is needed todefine the non-perpendicularity of the defined axes. Three finalparameters are needed to define the heliostat's orientation in a globalthree-axis reference frame.

One method of defining these nine parameters is to use anover-constrained mathematical system. Precisely aligning a heliostatwith this method requires a relatively large number of accurate samplesthat include information about the heliostat's geometric location andcurrent pan/tilt angles relative to a known angle. The main problem withthe current calibration approach is that in order to obtain an accurateand diverse set of samples, each heliostat must be calibrated relativeto an accurately positioned sun or light-sensing device. For largeheliostats (e.g., >20 m²) this may be accomplished with an attached sunsensor that tracks the sun throughout a day and compares known sunangles to angles measured by the heliostat's encoder system. Fieldworkers must move this sun tracker from heliostat to heliostat until thecalibration process is complete. For smaller heliostats this approach isnot cost-effective as the reflecting area decreases while the amount oflabor required per heliostat remains fixed. Micro-heliostat installershave attempted to solve this problem by placing sun sensors at knowngeometric locations in a field, and calibrating each heliostat to thesesensors. This approach is problematic, as it requires preciseinstallation of calibration towers/sensors and places constraints onheliostat installation flexibility that factor into the fully loadedsystem cost.

Similarly, calibration of photovoltaics (PVs) and concentratedphotovoltaics (CPVs) trackers requires knowledge of the solar surface'sorientation in a 3 axis global reference frame relative to a home panand tilt position.

SUMMARY

A robotic controller for autonomous calibration and inspection of two ormore solar surfaces wherein the robotic controller includes a drivesystem to position itself near a solar surface such that onboard sensorsmay be utilized to gather information about the solar surface. Anonboard communication unit relays information to a central processingnetwork, this processor combines new information with stored historicaldata to calibrate a solar surface and/or to determine its instantaneoushealth.

Particular embodiments and applications of the present invention areillustrated and described herein, it is to be understood that theinvention is not limited to the precise construction and componentsdisclosed herein and that various modifications, changes, and variationsmay be made in the arrangement, operation, and details of the methodsand apparatuses of the present invention without departing from thespirit and scope of the invention which is set forth in the claims.

In an embodiment, the mobile robotic controller may discover itsposition in a global or relative reference frame through the use of anonboard global positioning system or triangulation system.

In a second embodiment, the mobile robotic controller may discover itsposition in a global or relative reference frame through the use of anexternal total station, distance sensing system, natural light camerasystem, or structured light camera system.

In a third embodiment, the mobile robotic controller may use its knownposition in a global or relative reference frame to determine a solarsurface's geometric origin in a global or relative reference framethrough the use of an onboard distance sensing system, natural lightcamera system, or structured light camera system.

In a fourth embodiment, the mobile robotic controller may discover itsorientation in a global 3-axis reference frame through the use of anonboard magnetic compass, gyrocompass, solid state compass,accelerometer, inclinometer, magnetometer, gyroscope, or solar sensor.

In a fifth embodiment, the mobile robotic controller may use its knownorientation in a global 3-axis reference frame to determine the 3-axisorientation of a solar surface through the use of an onboard distancesensing system, natural light camera system, or structured light camerasystem.

In a sixth embodiment, the mobile robotic controller may use its knownorientation in a global 3-axis reference frame to determine andcharacterize the non-perpendicularity of a solar surface's pedestal axisthrough the use of an onboard distance sensing system, natural lightcamera system, or structured light camera system.

In a seventh embodiment, the mobile robotic controller may use anonboard light detection system in conjunction with a light tube or lightguiding system to determine if a solar surface is aligned to the sun.

In an eighth embodiment, the mobile robotic controller may useinstantaneous power output information from a PV cell or CPV module todetermine if a solar surface is aligned to the sun.

In a ninth embodiment, the mobile robotic controller may utilize anonboard repositionable light source that shines light onto a solarsurface in order to dither the power generated by a solar surface. Thisdither signal may be used to determine the health of a solar surface.

In a tenth embodiment, the mobile robotic controller may use datacollected from a multiplicity of solar surfaces to generate a map of thefield of solar surfaces. This virtual map may be used to optimizebacktracking algorithms.

In an eleventh embodiment, the mobile robotic controller may use amultiplicity of collected data points from a solar surface tocharacterize manufacturing errors, to determine current and historicsystem backlash, to characterize field installation tolerances, and tocharacterize ground settling.

In an thirteenth embodiment, the mobile robotic controller maycommunicate information gathered about a solar surface with an onboardprocessing unit, central processing unit, or distributed processingunits located on individual solar surfaces or other robotic controllers.

The features and advantages described in the specification are not allinclusive and, in particular, many additional features and advantageswill be apparent to one of ordinary skill in the art in view of thedrawings and specification. Moreover, it should be noted that thelanguage used in the specification has been principally selected forreadability and instructional purposes, and may not have been selectedto delineate or circumscribe the inventive subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 demonstrates an embodiment of a robotic controller that iscapable of determining its position in a field of solar surfaces usingonboard components.

FIG. 2 demonstrates an embodiment of a robotic controller that iscapable of determining its position in a field of solar surfaces usingonboard components in conjunction with calibrated in-field sensors.

FIG. 3 demonstrates one method a robotic controller may use to discoverthe distance to a heliostat or solar tracker's geometric origin.

FIG. 4 demonstrates a process a robotic controller may use to determinethe location of an individual solar surface.

FIG. 5 demonstrates an embodiment of a robotic controller that iscapable of determining its orientation in a global 3-axis referenceframe.

FIG. 6 demonstrates one method a robotic controller may use to discoverthe relative 3-axis orientation of a solar surface and its verticalpedestal axis.

FIG. 7 demonstrates a process a robotic controller may use to determinethe orientation of a solar surface in a global 3-axis reference frame.

FIG. 8 demonstrates a process a robotic controller may use tocharacterize the non-perpendicularity of a solar surface's supportingpedestal axis.

FIG. 9 demonstrates a light guide system that may be used by a roboticcontroller to determine if a solar surface is currently oriented towardthe sun.

FIG. 10 demonstrates one embodiment of a current monitoring system thatmay be used by a robotic controller to determine the instantaneousoutput of a PV cell or CPV module.

FIG. 11 demonstrates one embodiment of a light modulation system thatmay be used by a robotic controller to dither the amount of lightstriking a solar surface.

FIG. 12 demonstrates a process a robotic controller may use to optimizefield level backtracking algorithms.

FIG. 13 demonstrates a process a robotic controller may use tocharacterize field installation tolerances, manufacturing errors,backlash, and ground settling over time.

FIG. 14 demonstrates an embodiment of a robotic controller that iscapable of communicating raw or processed data to an onboard processingunit, central processing unit, distributed processing units, or withother robotic controllers.

DETAILED DESCRIPTION OF THE INVENTION

A preferred embodiment of the present invention is now described withreference to the figures where like reference numbers indicate identicalor functionally similar elements. Also in the figures, the left mostdigits of each reference number corresponds to the figure in which thereference number is first used.

Reference in the specification to “one embodiment” or to “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiments is included in at least oneembodiment of the invention. The appearances of the phrase “in oneembodiment” or “an embodiment” in various places in the specificationare not necessarily all referring to the same embodiment.

Some portions of the detailed description that follows are presented interms of algorithms and symbolic representations of operations on databits within a computer memory. These algorithmic descriptions andrepresentations are the means used by those skilled in the dataprocessing arts to most effectively convey the substance of their workto others skilled in the art. An algorithm is here, and generally,conceived to be a self-consistent sequence of steps (instructions)leading to a desired result. The steps are those requiring physicalmanipulations of physical quantities. Usually, though not necessarily,these quantities take the form of electrical, magnetic or opticalsignals capable of being stored, transferred, combined, compared andotherwise manipulated. It is convenient at times, principally forreasons of common usage, to refer to these signals as bits, values,elements, symbols, characters, terms, numbers, or the like. Furthermore,it is also convenient at times, to refer to certain arrangements ofsteps requiring physical manipulations or transformation of physicalquantities or representations of physical quantities as modules or codedevices, without loss of generality.

However, all of these and similar terms are to be associated with theappropriate physical quantities and are merely convenient labels appliedto these quantities. Unless specifically stated otherwise as apparentfrom the following discussion, it is appreciated that throughout thedescription, discussions utilizing terms such as “processing” or“computing” or “calculating” or “determining” or “displaying” or“determining” or the like, refer to the action and processes of acomputer system, or similar electronic computing device (such as aspecific computing machine), that manipulates and transforms datarepresented as physical (electronic) quantities within the computersystem memories or registers or other such information storage,transmission or display devices.

Certain aspects of the present invention include process steps andinstructions described herein in the form of an algorithm. It should benoted that the process steps and instructions of the present inventioncould be embodied in software, firmware or hardware, and when embodiedin software, could be downloaded to reside on and be operated fromdifferent platforms used by a variety of operating systems. Theinvention can also be in a computer program product that can be executedon a computing system.

The present invention also relates to an apparatus for performing theoperations herein. This apparatus may be specially constructed for thepurposes, e.g., a specific computer, or it may comprise ageneral-purpose computer selectively activated or reconfigured by acomputer program stored in the computer. Such a computer program may bestored in a computer readable storage medium, such as, but is notlimited to, any type of disk including floppy disks, optical disks,CD-ROMs, magnetic-optical disks, read-only memories (ROMs), randomaccess memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards,application specific integrated circuits (ASICs), or any type of mediasuitable for storing electronic instructions, and each coupled to acomputer system bus. Memory can include any of the above and/or otherdevices that can store information/data/programs. Furthermore, thecomputers referred to in the specification may include a singleprocessor or may be architectures employing multiple processor designsfor increased computing capability.

The algorithms and displays presented herein are not inherently relatedto any particular computer or other apparatus. Various general-purposesystems may also be used with programs in accordance with the teachingsherein, or it may prove convenient to construct more specializedapparatus to perform the method steps. The structure for a variety ofthese systems will appear from the description below. In addition, thepresent invention is not described with reference to any particularprogramming language. It will be appreciated that a variety ofprogramming languages may be used to implement the teachings of thepresent invention as described herein, and any references below tospecific languages are provided for disclosure of enablement and bestmode of the present invention.

In addition, the language used in the specification has been principallyselected for readability and instructional purposes, and may not havebeen selected to delineate or circumscribe the inventive subject matter.Accordingly, the disclosure of the present invention is intended to beillustrative, but not limiting, of the scope of the invention.

Referring now to the drawings, FIG. 1 demonstrates an embodiment of arobotic controller that is capable of determining its position in afield of solar surfaces using onboard components. A robotic controllermay be repositioned near a first (101) and second solar surface (106).Methods of achieving this motion include, but are not limited to; anexternal system or collection of systems that physically move therobotic controller in an unstructured environment, an external system orcollection of systems that physically move the robotic controller in astructured environment, an onboard system or collection of systems thatenable the robot to move itself autonomously in an unstructuredenvironment, an onboard system or collection of systems that enable therobot to move itself autonomously in a structured environment, acombination of onboard and external systems that enable the robot tomove itself autonomously in an unstructured environment, and acombination of onboard and external systems that enable the robot tomove itself autonomously in a structured environment. FIGS. 1-14 assumethat the robotic controller is capable of using an onboard collection ofsensors and electromechanical systems to move itself autonomously in anunstructured environment. Prior disclosures, notably U.S. provisionalapplication number 61/364,729 filed on Jul. 15, 2010, U.S. provisionalapplication number 61/419,685 filed on Dec. 3, 2010, US utilityapplication Ser. No. 13/118,274, and US utility application Ser. No.13/182,297, describe methods of autonomously repositioning a roboticcontroller in a structured or unstructured environment in more detail.

In order to achieve autonomous outdoor position sensing and navigationusing only onboard components in an unstructured environment, a roboticcontroller may be equipped with a flight system and system of flightcontrols such that it does not have to encounter ground based obstacles.A ground based robotic controller must include a collection of systemscapable of navigating through a) 3-dimensional terrain; b) changes insurface density; c) weather exigencies and d) instability of the sensedenvironment. One existing method of achieving these goals is for therobotic controller to: a) map the terrain with 3-D vision systems, b)compute safe and unsafe areas on the terrain within this field ofvision, c) compute optimal paths across the safe area towards thedesired destination, d) activate a drive mechanism, which may includedrive motors, wheels, and associated electronics, e) repeat this cycleuntil the destination is reached, or there is no known path to thedestination. A notable obstacle the robotic controller (104) mayrecognize is a solar surface (101), its supporting structure system(102), and its supporting foundation (103).

An embodiment of the robotic controller will now be described. Itincludes a drive mechanism (105) to move itself between a first solarsurface (101) and a second solar surface (106). The drive mechanismutilizes a multiplicity of wheels connected to an electric drive motorto propel the robotic chassis over sections of terrain separating solarsurface calibration stations (107) where station is defined as a generalarea near a first or second solar surface. The robotic controller mayutilize a battery-based power unit to provide electrical energy to thedrive motor and to other enable electronic functions. An onboard 3-Dvision system (108) may use a structured or natural light based camerasystem to recognize unique solar surfaces or ground obstacles (109). Anonboard microprocessor system may be used to compute safe drive areas,an optimal drive path (110), and may send commands to the drive system'selectric motors to execute the optimal drive path.

A robotic controller may include an onboard position location system(111) that is capable of determining the location of a roboticcontroller in global coordinates. During operation, the onboard positionlocation system may constantly update its position in global (X, Y, Z)coordinates. This system may be made functional through the use of a GPSdevice or triangulation system that is able to communicate with amultiplicity of devices calibrated in a global reference frame. In atriangulation system, three triangulation receivers/transmitters maycommunicate with a system onboard the robotic controller. In oneembodiment, the mobile triangulation system measures the time delaybetween signals to determine the raw distance to each triangulationtransmitter. These signals may be optical, electromagnetic, or audible.If the geometric location of these three transmitters is known, thetriangulation device will be able to determine its relative or globalposition in a field of solar surfaces. A robotic controller may also usea 3-D vision system (108) and SLAM algorithms to determine its relativeposition in a field of solar surfaces.

FIG. 2 demonstrates an embodiment of a robotic controller that iscapable of determining its position in a field of solar surfaces usingonboard components in conjunction with calibrated in-field sensors thatserve as a minimally structured environment. In an embodiment, therobotic controller may include an onboard target (201) that correspondswith an autonomous total station (202). In this configuration, the totalstation is placed at a known location (203), and the robot (104)automatically moves a retro reflective target (201) throughout theinstallation field. The total station is capable of measuring thedistance to the retro reflective target and communicates the target'srelative position to the mobile robotic controller (104). Other systemsand/or methods for sensing position include, but are not limited to;utilizing a distance sensing system onboard the robotic controller thatis able to determine its distance to a multiplicity of calibrated towersor targets, utilizing one or more natural light based camera or camerasto determine distance to calibrated targets or towers, or utilizing astructured light based position sensing techniques.

In systems where the robotic controller's environment is sufficientlyconstrained, this data may be used to assist the robot in determiningits position in a field of solar surfaces. For example, if the roboticcontroller travels along a rigid line structure, it may use amultiplicity of position readings to fit all position points to anapproximate line using a least squares method.

FIG. 3 demonstrates one system a robotic controller may use to discoverthe distance to a heliostat or solar tracker's geometric origin. A solarsurface's geometric origin (301) may be defined as the point about whichthe surface pivots. A structured light camera system (302), thatcomprises a structured light emitter and sensor, may be used to sensethe distance, in X, Y, Z coordinates, from the robotic controller to asolar surface's geometric origin (301) or to a mark (303) on the solarsurface's support structure (102) or foundation (103). This mark mayhave a pre-defined offset to the geometric origin. By determining itsdistance to this point, a robotic controller may then approximate itsdistance to a solar surface's origin by applying a pre-defined geometricoffset.

Other systems that could be used by the robotic controller to accomplisha similar objective include, but are not limited to; utilizing a naturallight based camera or system of cameras, utilizing a laser distancesensor or sensors, utilizing a physical probing system, or by utilizinga system capable of detecting a signal emitted by the solar surface orby a point on its supporting structure or supporting foundation. A mark(303) or group of marks on an individual solar surface may include, butare not limited to a retro-reflective target, a color coded target, aunique physical feature of the solar surface or its supportingstructure, or a signal emitting device that emits a magnetic,electromagnetic, or audible signal.

If the robotic controller's environment is more constrained, thisinformation may be used to assist the robot in determining the distanceto a solar surface's geometric origin. As an example, if the roboticcontroller is constrained to a geometric line with a known offset from asolar surface's geometric origin (301), the robotic controller will onlyhave to compute its offset in one dimension as the other two dimensionscan be assumed.

FIG. 4 demonstrates a process a robotic controller may use to determinethe location in global or relative coordinates of two or moreindividually controlled solar surfaces. This process combines methodsand processes outlined in FIGS. 1-3.

The calibration process begins with step 401, generating a 3-D map ofsurroundings. This map enables the robotic controller to compute safeand unsafe areas in the terrain (402). The robotic controller isequipped with a station sensing system that may detect distance toindividual solar surfaces and this information, combined with computedsafe areas, can be used to compute the optimal path to the next stationor calibration zone (403). In an embodiment, the robotic controller hasone or more onboard cameras that are able to detect key features onindividual heliostats. Other embodiments include but are not limited to:each heliostat emitting a signal that is intercepted by a device on thecalibration robot that measures signal attenuation, equipping the robotwith a SONAR or LiDAR based system in order to map and analyzesurroundings, utilizing a time of flight based 3-D scanning system, orutilizing a laser distance sensor system in combination with aretro-reflective target strategically placed on a solar surface or itssupporting structure.

In step 404, the robotic controller activates its drive mechanism tomove towards a station or calibration zone. While moving betweenstations, the station sensing mechanism may be used to continuallyupdate the optimal drive path to the drive mechanism (405) until thedestination is reached. In this example, the destination is defined bythe robotic controller being within range to calibrate a solar surface.Process steps 401-405 are similar for drive mechanisms that utilizewheels, caterpillar tracks, moveable legs, articulating joints, or achain drive to reposition the robotic controller. In alternativeembodiments, drive systems can use a track, cable, or rail basedmechanisms to reposition the controller between stations. The roboticcontroller may communicate with an external drive or set of drives toperform this repositioning.

In step 406, the robotic controller may access an onboard positionlocation mechanism to discover its absolute or relative position in 3Dspace. As outlined in FIGS. 1-2, this may be accomplished with areal-time kinematic global positioning system that discovers positioninformation at high accuracy in a global reference frame. Other methodsof determining position in 3D space include but are not limited to: astandard global positioning system, triangulation from known sensorsemitting sound or light, sensors on the robot measuring distance toknown locations, a camera based system recognizing patterns at variousdistances, or communicating with a manual or automatic total stationsurveying system.

After a robotic controller enters a calibration zone and determines itsposition and in a global reference frame (406), it uses adistance-sensing mechanism and/or known geometry to discover theabsolute distance, in X, Y, Z coordinates, to a solar surface'sgeometric origin (407). The robotic controller can apply this originoffset to its known position to compute the geometric location of asolar surface in a global reference frame (408). For example, if arobotic controller identifies itself at a global position of X=4000,Y=4000, and Z=4000 and recognizes that a heliostat's origin point is atdistance of X=1, Y=2, and Z=3 from the calibration robot's referencepoint, it would calibrate the solar surface's origin point at X=4001,Y=4002, and Z=4003 in a global reference frame.

The calibration robot may then communicate positioning data about anindividual solar surface (409) to an onboard data storage unit, acentral communications system, or a distributed communications system.In an embodiment, the calibration robot includes a wireless transmitter.Other embodiments for transmitting data include but are not limited to:wireless communication to individual solar surfaces, wirelesscommunication to a group of solar surfaces or central controller, directdata link to individual solar surfaces, direct data link for amultiplicity of solar surfaces or central controller, data transferthrough the calibration robot's power supply, or by wirelessly writingcalibration data to a storage medium or RFID chip.

After the calibration process is complete (steps 401-409), thecalibration robot determines if there are more solar surfaces tocalibrate (410). If more solar surfaces need to be calibrated, theprocess repeats with step 401. If all heliostats have been calibrated,the robotic controller may return to its home or docking position (411).This dock may include a recharging station or a data link to storeinformation or to communicate calibration data to a central controller.

FIG. 5 demonstrates an embodiment of a robotic controller (104) that iscapable of determining its orientation in a global 3-axis referenceframe (501). In this embodiment, the robot utilizes an onboardaccelerometer to determine orientation relative to gravity and amagnetic compass to determine orientation relative to the earth'smagnetic poles. Other methods of properly calibrating the robot to aglobal reference frame include but are not limited to: an onboardgyrocompass, solid state compass, GPS compass, inclinometer,magnetometer, gyroscope, or a solar sensor. A solar sensor could be usedto determine a robotic controller's orientation relative to theinstantaneous solar vector. By determining the current time, andcombining this information with approximate GPS coordinates, a roboticcontroller would be able to map its orientation relative to the sun to aglobal 3-axis reference frame (501).

FIG. 6 demonstrates one method a robotic controller may use to discoverthe relative 3-axis orientation of a solar surface and its verticalpedestal axis. In this method, a structured light camera system (302)that comprises a structured light emitter and sensor may be used tosense the relative orientation of a solar surface (101) and its verticalpedestal axis (103). This camera system may be static, or dynamic toincrease the effective field of view. The structured light emitter mayproject a pattern of dots (601) onto the solar surface (101), itssupporting structure (102), and its supporting foundation (103).Information obtained from a sensor or camera able to detect thisstructured light pattern can be used to detect features and to fit thesefeatures to a geometric plane.

A solar surface repositioning system may also include features thatassist a mobile robotic controller in this orientation discoveryprocess. These features include, but are limited to: retro-reflectivetargets placed in pre-defined patterns, a color coded target, a uniquephysical feature of the solar surface or its supporting structure, or asignal emitting device that emits an electromagnetic or audible signal.

Other methods of determining a solar surface's orientation relative to arobotic controller include, but are not limited to: utilizingpre-defined or discovered geometry, utilizing a natural light basedcamera, utilizing a light or sound based distance sensing system, orutilizing a probing system that interacts with physical elements of thesolar surface or detects magnetic, electromagnetic, or audible signalsemitted by known locations on the solar surface. This probing systemcould also be used to place an inclinometer on or near a solar surface'svertical pedestal axis to directly compute its non-perpendicularity.

FIG. 7 demonstrates a process a robotic controller may use to determinethe orientation of a solar surface in a global 3-axis reference frame.This process begins with steps 401-405 as outlined in detail in FIG. 4.In step 701, the robotic controller may access an onboard orientationdiscovery mechanism to discover its orientation in a global referenceframe. As outlined in FIGS. 5-6 this may be accomplished with an onboardaccelerometer and compass that orients the calibration robot withrespect to a global reference frame.

The robotic controller's processing unit may now request informationfrom onboard sensors that are used to determine the relative orientationof a solar surface (702). This information may then be mapped to aglobal reference frame (703) by projecting a solar surface's relativeorientation onto the robot's discovered global orientation. Thecalibration robot may then communicate orientation data about anindividual solar surface (704) to an onboard data storage unit, acentral communications system, or a distributed communications system.

After the calibration process is complete, the calibration robotdetermines if there are more solar surfaces to calibrate (410). If moresolar surfaces need to be calibrated, the process repeats with step 401.If all heliostats have been calibrated, the robotic controller mayreturn to its home or docking position (411).

FIG. 8 demonstrates a process a robotic controller may use tocharacterize the non-perpendicularity of a heliostat's pedestal axisusing a perpendicularity unit within the robotic controller, thisperpendicularity unit can take the form of a software algorithm, forexample. This process begins with steps 401-405 as outlined in detail inFIG. 4 and step 701 as outlined in FIG. 7. The robotic controller'sprocessing unit may now request information from onboard sensors thatare used to determine the relative orientation of a solar surface'spedestal axis (801). This information may then be mapped to a globalreference frame (802) by projecting a pedestal axes relative orientationonto the robot's discovered global orientation. As a final step in thecalibration process, the robotic controller will compare the offset ofthe discovered global orientation to a known or approximatedgravitational vector to compute the non-perpendicularity of the solarsurface's pedestal axis (803).

The calibration robot may then communicate the non-perpendicularity of asolar surface's foundation or pedestal axis (804) to an onboard datastorage unit, a central communications system, or a distributedcommunications system. After the calibration process is complete, thecalibration robot determines if there are more solar surfaces tocalibrate (410). If more solar surfaces need to be calibrated, theprocess repeats with step 401. If all heliostats have been calibrated,the robotic controller may return to its home or docking position (411).

FIG. 9 demonstrates a light guide system that may be used by a roboticcontroller to determine if a solar surface is currently oriented towardthe sun. An embodiment of this system requires that robotic controllerbe equipped with a light sensing device (901). This device is able tosense the output of a light guide system (905) that comprises a narrowband optic (902), a fiber optic cable (903), and an optional lightscattering optic (904). The narrow band optic prevents off-axis directsunlight from entering the fiber optic cable, and has sensitivity to asolar half angle range that can be predefined or adjusted as needed. Thepurpose of the fiber optic cable is to enable better access to the data,namely the light output or lack thereof, coming from the narrow bandoptic as the cable may be routed as needed. The light scattering opticmay enable even better access to this data and eliminate the need for arobotic controller's light sensing device (901) to be placed near to theend of the fiber optic cable.

The purpose of this system is to determine if a solar surface iscurrently on sun. This information may be used as a closed loopcalibration technique in conjunction with a search algorithm thatsimultaneously adjusts the position of a solar surface while monitoringa robotic controller's light sensing device (901). It may also be usedto determine the orientation of a solar surface in a global referenceframe by utilizing approximate global position and an internal clock tocompute the current solar vector.

FIG. 10 demonstrates one embodiment of a current monitoring system thatmay be used by a robotic controller to determine the instantaneousoutput of a PV cell or CPV module. This purpose of this system is todetermine if a solar surface is aligned to the sun. As outlined in FIG.9, this information is useful when used in a closed loop calibrationtechnique or to determine the orientation of a solar surface in a globalreference frame. The current monitoring system (1001) is primarilyuseful for PV and CPV applications as it does not require any new systempieces, but could also be used in heliostat applications. The system isable to determine the instantaneous output of a photovoltaic orconcentrated photovoltaic system on an inverter, string, or individualpanel level through a variety of sensing techniques. These techniquesinclude, but are not limited to indirect current sensing by measuringthe magnetic field generated by a wire (1002) or loop of wire with aprobing hall effect sensor (1003), direct current sensing by physicallyplugging in a voltage and/or current meter into a photovoltaic system,or by connecting to an external metering device that is capable ofcommunicating instantaneous current output information to a roboticcontroller (104).

FIG. 11 demonstrates one embodiment of a light modulation system thatmay be used by a robotic controller to dither the amount of lightstriking a solar surface. One purpose of this system is to determine thestatus or overall health of an individual solar surface by measuring thesystem's output while simultaneously modulating the amount of artificialor natural light striking the solar surface. If no power output changeis detected at a system level while one statistically significant pieceof the solar power system is effectively turned on/off, it may beassumed that aforementioned solar surface is dysfunctional.

One method of achieving this dithering effect will now be described. Thesystem uses an onboard directional light emission device (1101) toincrease the amount of light striking a solar surface (101). When thelight emission device is turned off, the amount of light striking asolar surface decreases. The system may be used during daylight hours,though the modulation signal is more statistically significant atnighttime when a system's baseline power output is approximately zero.

FIG. 12 demonstrates a process a robotic controller may use to optimizefield level backtracking algorithms. Backtracking algorithms are onlyapplicable to non-concentrating PV applications as they require a solarsurface to be pointed away from the solar vector in order to preventshading. Shading an area of a PV module can produce a disproportionalpower loss.

This process begins with executing the processes described in FIGS. 4,7, and 8 to determine the current position, orientation, andnon-perpendicularity of an individual solar surface and its pedestalaxis (1201). Process 1201 is then repeated for every solar surface thatmay be affected by a backtracking analysis (1202). These groups of solarsurfaces may be pre-defined or pre-programmed. The robotic controllermay also be used to determine or discover safe zones wherein safe zonesare defined as places where it would be impossible, given a known ordiscovered field configuration, for a first solar surface to shade asecond solar surface.

The collected information is then used to generate a 3D map of a fieldof solar surfaces (1203). In order to determine if solar surfaces arecurrently a) shading each other or b) have the capacity to shade eachother, the geometry and area of the solar surfaces must be defined. Arobotic controller may use onboard vision systems to detect geometry andarea for an individual solar surface, or this information may be definedby a human operator (1204). To determine if a solar surface is shadingan adjacent solar surface, a directional light simulating the solarvector may be applied to the generated 3D map of solar surfaces(1205),If shading is detected, a computational system may determine theminimum amount of change needed to a first solar surface's orientationto prevent it from shading a second solar surface (1206). Thiscomputational process may be repeated for future orientations of solarsurfaces (1207) and future solar vector angles to pre-determine theoptimal positioning for individual solar surfaces in a field of solarsurfaces (1208).

FIG. 13 demonstrates a process a robotic controller may use tocharacterize field installation tolerances, manufacturing errors,backlash, and ground settling over time. These errors that arise fromimperfections in the manufacturing and installation processes may bedefined by comparing a set of historic data points containinginformation about the measured orientation and/or position of a solarsurface to its predicted orientation and/or position if no errorsexisted. This process may begin with executing processes described inFIGS. 4, 7, and 8 to determine the current position, orientation, andnon-perpendicularity of an individual solar surface and its pedestalaxis (1201). Process 1201 is then repeated for a solar surface to createa historic data set (1301). In step 1302, a solar surface's estimatedorientation and the known solar vector are also recorded. Acomputational system may then compare measured, predicted, and knowndata to create an error map against solar positioning and against asolar surface's predicted orientation (1303). This error detectionprocess may be used to detect solar surfaces that fall out of anacceptable range of error. This error map may also be used to fine tunesun tracking or backtracking control algorithms by effectively closingthe calibration loop.

FIG. 14 demonstrates an embodiment of a robotic controller (104) that iscapable of communicating raw or processed data to an onboard processingunit, central processing unit (1401), distributed processing units(1402), or with other robotic controllers (1403). In alternateembodiments, a robotic controller can communicate with and receiveinformation from the one or more solar surfaces even when the roboticcontroller is are not adjacent to the one or more solar surfaces.

While particular embodiments and applications of the present inventionhave been illustrated and described herein, it is to be understood thatthe invention is not limited to the precise construction and componentsdisclosed herein and that various modifications, changes, and variationsmay be made in the arrangement, operation, and details of the methodsand apparatuses of the present invention without departing from thespirit and scope of the invention as it is defined in the appendedclaims.

1. A system for calibrating a robotic controller to multiple solarsurfaces comprising: a first solar surface of the multiple solarsurfaces coupled to a first support structure; a second solar surface ofthe multiple solar surfaces coupled a second support structure; and therobotic controller, including a drive system for positioning the roboticcontroller; sensors for identifying status information about said firstsolar surface when the robotic controller is positioned near said firstsupport structure, and to identify status information about said secondsolar surface when said robotic controller is positioned near saidsecond support structure; and a calibration system, to calibrate saidfirst solar surface when the robotic controller is positioned near saidfirst support structure, and to calibrate said second solar surface whensaid robotic controller is positioned near said second supportstructure.
 2. The system of claim 1, wherein said calibration systemincludes: a solar surface orientation detection unit to determine anorientation of said first solar surface, and an orientation of saidsecond solar surface.
 3. The system of claim 2, wherein said solarsurface orientation detection unit identifies solar surface targetspositioned on the back side of said first and second solar surfaces. 4.The system of claim 3, wherein said solar surface targets are at leastone of colored targets, patterned targets, a physical feature of theback of said first solar surface, and/or a signal emitting device. 5.The system of claim 2, wherein said calibration system includes: anorientation unit to determine robotic controller orientation informationof the robotic controller wherein said robotic controller orientationinformation includes a value representing the tilt of the roboticcontroller; and a perpendicularity unit to determine the orientation ofsaid first support structure and the orientation of said second supportstructure using said robotic controller orientation information, whereinsaid status information includes said orientation of said first andsecond support structure.
 6. The system of claim 5, wherein saidperpendicularity unit determines a first difference representing adifference between the direction of an axis of the first supportstructure and a direction of gravitational force and determines a seconddifference representing a difference between the direction of an axis ofthe second support structure and said direction of gravitational force.7. The system of claim 5, wherein said calibration system includes: afirst solar surface directionality device to determine a first alignmentvalue representing how closely said first solar surface is aligned withthe sun; a second solar surface directionality device to determine asecond alignment value representing how closely said second solarsurface is aligned with the sun; and wherein said robotic controllerincludes an alignment unit to modify a direction of said first andsecond solar surfaces to efficiently align with the sun based on theoutput of the first and second solar surface directionality devices andwherein said status information includes said first and second alignmentvalues.
 8. The system of claim 7, wherein said robotic controllerincludes: a communication unit, disposed to receive said first alignmentvalue and said second alignment value and to transmit said first andsecond alignment values to a calibration computing device.
 9. The systemof claim 8, further comprising: said calibration computing device, togenerate first calibration instructions for said first solar surfacebased upon said first alignment values, to generate second calibrationinstructions for said second solar surface based upon said secondalignment values, and transmitting said first and second calibrationinstructions to said robotic controller.
 10. The system of claim 9,wherein said calibration computing device is located in said roboticcontroller.
 11. The system of claim 10, further comprising: a secondrobotic controller; and wherein said calibration computing devicetransmits said first calibration instructions to said first roboticcontroller, and wherein said calibration computing device transmits saidsecond calibration instructions to said second robotic controller. 12.The system of claim 9, where said calibration computing device islocated remotely from said robotic controller.
 13. The system of claim1, wherein said calibration system includes: a position detection deviceto determine a position of the robotic controller.
 14. The system ofclaim 13, wherein said calibration system identifies a first distancerepresenting a distance between the robotic controller and a firstgeometric origin of said first solar surface, and said calibrationsystem identifies a position of the geometric origin in at least one ofa local or global coordinate system based on said position of therobotic controller and said first distance.
 15. The system of claim 13,wherein said position detection device determines said position of therobotic controller using at least one of a global positioning systemdevice, a triangulation system, a distance sensing system and/or acamera system.
 16. The system of claim 1, wherein said calibrationsystem includes: an orientation unit to determine robotic controllerorientation information of the robotic controller wherein said roboticcontroller orientation information includes a value representing thetilt of the robotic controller; and a perpendicularity unit to determinethe orientation of said first support structure and the orientation ofsaid second support structure using said robotic controller orientationinformation wherein said status information includes said orientation ofsaid first and second support structure.
 17. The system of claim 1,wherein said calibration system includes: a first solar surfacedirectionality device to determine a first alignment value representinghow closely said first solar surface is aligned with the sun; a secondsolar surface directionality device to determine a second alignmentvalue representing how closely said second solar surface is aligned withthe sun; and wherein said robotic controller includes an alignment unitto modify a direction of said first and second solar surfaces toefficiently align with the sun based on the output of the first andsecond solar surface directionality devices and wherein said statusinformation includes said first and second alignment values.
 18. Thesystem of claim 17, wherein said robotic controller includes: acommunication unit, disposed to receive said first alignment value andsaid second alignment value and to transmit said first and secondalignment values to a calibration computing device.
 19. The system ofclaim 18, further comprising: said calibration computing device, togenerate first calibration instructions for said first solar surfacebased upon said first alignment values, to generate second calibrationinstructions for said second solar surface based upon said secondalignment values, and transmitting said first and second calibrationinstructions to said robotic controller.
 20. A method for calibrating arobotic controller to multiple solar surfaces including a first solarsurface of the multiple solar surfaces coupled to a first supportstructure and a second solar surface of the multiple solar surfacescoupled to a second support structure, the method comprising the stepsof: positioning a robotic controller near said first support structure;identifying first status information about said first solar surface;transmitting said first status information to a remote computing device;generating first calibration information for said first solar surface;positioning a robotic controller near said second support structure;identifying second status information about said second solar surface;transmitting said second status information to a remote computingdevice; and generating second calibration information for said secondsolar surface.